Water Intrusion in Volkswagen® Tail Lamp Area

Dan Espersen
ALLDATA® Collision^SM
Senior Program Manager

Vehicle manufacturers regularly publish Technical Service Bulletins (TSBs). These are updates to repair procedures, techniques, part numbers, equipment and materials, as well as repair information for known issues reported from repair facilities and customers.

Without prior knowledge of these updates, you and your team may service or repair a vehicle with outdated information. Or you may be chasing a problem not even be related to the collision or your repair. Researching TSBs prior to production can save your technicians many hours of valuable production time and will ultimately increase the overall cycle times with your customers' vehicles.

Here is a Technical Service bulletin that outlines a repair for a water leak around the tail light area on certain 2006 - 2008 Volkswagen models.

SERVICE INFORMATION
Always refer to ALLDATA® Collision^SM for safety procedures, identification of material types, recommended refinish materials, removal and installation procedures.

Always refer to Volkswagen for questions relating to applicable or non applicable warranty repair information.

AFFECTED VEHICLES
2006-2008 Volkswagen Rabbit® and GTI® (All)

REQUIRED PARTS
Tail lamp left - 1K6945095M
Tail lamp right - 1K6945096M

CONDITION
Water intrusion in the rear of the vehicle, around rear tail lamp area, or excessive accumulation of water visible inside the rear tail lamps.

CAUSE
Inadequate sealing surfaces, rear of body, and/or rear lights.

SERVICE PROCEDURE Water Leak Test The following preparation work must be performed before a leakage test.

• Remove affected side interior trim (Figure 1).
• Clear any visible signs of moisture with a dry cloth (Figure 2).
• Close tailgate and begin water test (Figure 3).
• Water test entire area around taillight and body (Figure 4).
• Continue to check taillight and interior of trunk for water intrusion (Figure 5).
• Water test up to and along flex boot (Figure 6).
• Check for any loose seals (Figure 6-7).
• Check the ball journal (mounting point of the tailgate damper (Figure 8).
• If there are no visible leaks inside the trunk or side panel:
  
  
  • Close the tailgate and allow water to flow over the vehicle for 7 minutes.
  • Continue to check the interior of the trunk for water intrusion (Figure 9).
  
  
• Carefully inspect all seams and welds (Figure 10-11-12)
• If water leaks are identified on the body, the vehicle must be repaired at the shop.
• If no water leaks are found:
  Visually inspect the rear taillights.



• Correct fit of rubber seals.
• Are there plastic sealing washers under mounting bolts of taillights?
• Welding seams on plastic housing correct?
• Check adjustment elements under taillight in the body shell for leaks.
• Assembly and fine seals under taillights not damaged.
• Is sealing area dirty in the contact surface of taillights?


• If leak test and taillight inspection prove inconclusive and no leaks are found:



• Replace taillight of affected side.

Written by Dan Espersen, ALLDATA Collision Program Manager. Dan is a Gold Pin Member of the Collision Industry Conference (CIC) and holds an AA Degree in Automotive Technology. He has 17 years of experience in the collision industry and 17 years of experience in the automotive industry.

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Volkswagen, Rabbit and GTI are registered trademarks of Volkswagen of America, Inc. All trademark names and model designations are being used solely for reference and application purposes.